FWS Group was commissioned to develop the Metakaolin Processing Plant, a cutting-edge facility designed to efficiently handle high-volume metakaolin production. The project involved designing and installing comprehensive infrastructure, processing systems, and equipment to ensure smooth and effective production, while meeting industry and environmental standards.

The goal of this project was to create a state-of-the-art processing facility capable of producing up to 200,000 tonnes of metakaolin annually. The plant was designed to support large-scale operations while ensuring operational efficiency, adherence to environmental regulations, and the long-term durability of the infrastructure.

Key features of the Metakaolin Processing Plant include:

• Processing Capacity: The facility is designed to handle up to 200,000 tonnes of metakaolin annually, allowing for large-scale production to meet both industrial and commercial demands.
• Foundations and Structural Elements: Extensive design and installation of concrete foundations and structural steel, creating a robust base for the plant’s infrastructure, ensuring stability and durability.
• Processing Equipment Installation: The plant is equipped with a variety of processing equipment, including:
  • Primary Crusher: For initial ore reduction.
  • Ore Handling Equipment: To efficiently transport and manage ore throughout the process.
  • Rotary Dryer/Kiln/Cooler: For drying, calcining, and cooling metakaolin.
  • Mechanical Separator: For separating metakaolin based on physical properties.
  • Baghouse and Stack: For dust collection and emissions control.
  • Secondary Dust Collectors: To capture additional dust.
  • Coal Mill: For grinding coal used in the kiln.
  • Ore Conditioner: To prepare ore for processing.
  • Ore and By-Product Bins: For storing processed materials and by-products.
  • Truck Scale and Loading Facility: For accurate measurement and efficient loading of finished products.

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The Metakaolin Processing Plant project successfully delivered a fully operational facility capable of processing high volumes of metakaolin. The integration of advanced processing systems and equipment ensures efficient production while maintaining compliance with environmental standards, supporting large-scale industrial and commercial demands.